Apparatus for the production assembly of articles of furniture or the like

ABSTRACT

The invention is directed to a novel production machine for articles of furniture or the like (e.g., boxes, display assemblies, packaging or other assembly of parts), utilizing automatic fastening equipment, such as staple guns. The invention is particularly characterized by the provision of simplified, universally adjustable facilities for the mounting and manipulating of the staple guns, during an assembly operation, enabling the assembly to be completed rapidly and expeditiously. Resetting of the machine for various configurations of assembly articles is greatly facilitated with the equipment of the invention.

United States atet Inventors Arthur Sack 240-37 De Pew Ave, Douglaston, N.Y. 1 1363; Stephen A. D'Alessio, 209-02 43rd. Ave., Bayside, N.Y. 11061 Appl. No. 812,985 Filed Apr. 3, 1969 Patented Feb. 2, 1971 APPARATUS FOR THE PRODUCTION ASSEMBLY OF ARTICLES OF FURNITURE OR THE LIKE [56] References Cited UNITED STATES PATENTS 2,188,053 1/1940 Madsen 227/152UX 2,540,106 2/1951 Eichelberger 22'7/152 2,544,499 3/1951 Hovey 227/153 Primary ExaminerGranville Y. Custer, Jr. Attorney-Mandeville and Schweitzer ABSTRACT: The invention is directed to a novel production machine for articles of furniture or the like (e.g., boxes, display assemblies, packaging or other assembly of parts), utilizing automatic fastening equipment, such as staple guns. The invention is particularly characterized by the provision of sim- 6 Clalms4 Drawing Figs plified, universally adjustable facilities for the mounting and US. Cl 227/152, manipulating of the staple guns, during an assembly operation, 227/ 153 enabling the assembly to be completed rapidly and expedi- Int. Cl B25c 7/00 tiously. Resetting of the machine for various configurations of Field of Search 227/151, assembly articles is greatly facilitated with the equipment of 152, 153, 154 the invention.

as 26 I3 69 3| gg i 5 4a A 4 3 37 am v 52 r O O 68 0 O 0 0 43 m!" 0 Q 4 as F a 36m 70 iii --i 5s f rim 4| 2 41 ll/ 1" l as: 33 5e Q 39 w 0 O "1" O O O 1 e9 e2 e9 23 M 24 2g 20 a 12 t5 l I ,-n

PATENIED FEB 2 |97| 3; 5 59 863 SREET 1 0F 3 INVENTORS ARTHUR SACK STEPHEN A. D'ALESSIO BY 771M i ATTORNEYS mama] FEB 2m?! 3555.863

sum 2 OF 3 v NINVENTORS ARTHUR SACK. STEPHEN A. DALESSIO ATTORNEYS pmmwnamn 31559 .863

suma nrs I 36b V INVENTORS ARTHUR SACK p STEPHEN A. DALESSIO I 6 BY {/9 ATTORNEYS APPARATUS FOR THE PRODUCTION ASSEMBLY OF ARTICLES OF FURNITURE OR THE LIKE BACKGROUND OF INVENTION In the production assembly of certain articles of furniture, for example, it is a conventional practice to secure together wooden parts by the use of automatic fastening equipment, such as pneumatic stapling guns. The assembly operation, using such guns, can be accomplished with much greater speed and facility than with, for example, hammer and nails. A particularly common application of such production techniques is in the assembly of drawers for desks and bureaus, and the invention is particularly applicable to, although not necessarily limited to, the high speed, production assembly of drawers.

In a typical assembly operation for a wooden drawer, using staple gun fasteners, the two sidewall panels and two end wall panels of the drawer are inserted in a suitable jig, which temporarily retains the panels in the desired configuration. One or more production assemblers then manually apply a staple gun or guns to the assembled parts to secure them together at the various joints.

Although the desirability of further automating such production operations has been apparent, the actual accomplishment thereof has not been realized, heretofore, because typical production runs may be quite short, and production economies realized through conventional automation may compare unfavorably with the economics of manual production, taking into account investment and maintenance requirements for a typical automated apparatus, setup time, etc.

SUMMARY OF INVENTION In accordance with the present invention, a novel production machine is provided for the staple gun assembly of articles of furniture, such as drawers, which is sufficiently simplified in its design, construction, and operation as to compare in a substantially superior manner with the conventional assembly techniques, taking into consideration all of the relevant factors such as capital and maintenance costs, plant floor space, setup time requirements, and the like. The equipment of the invention, while being of sufficiently simplified construction to enable its utilization at very low cost, significantly increases the rate of assembly of articles such as drawers and the like and thus greatly improves the overall economics of the operation.

More specifically, the apparatus of the invention comprises a main frame structure on which is removably mounted a suitable assembly jig, arranged to receive and temporarily secure a plurality of assembly components, such as the four frame panels of a drawer. A pair of transverse supports are disposed in straddling relation to the assembly jig, and desirably one of these supports is longitudinally adjustable on the frame while the other has a fixed relationship with the assembly jig. Each support mounts two or more staple guns, with one of the guns on each support typically being secured in fixed relation thereto, while provision is made for the transverse adjustment of the others.

The arrangement of machine components is such that, when the assembly jig is installed on the frame, it is initially properly aligned with the fixed gun on the fixed support. Following longitudinal adjustment of the movable support, the fixed gun on that support is properly aligned with the jig. Thereafter, the movable guns are adjusted transversely into proper alignment.

In a production sequence, the jig is loaded with and temporarily retains the assembly parts, the staple guns having been aligned with the joints to be secured. Upon actuation of the machine, all of the guns will be actuated simultaneously to inject fastening devices into the joints.

In accordance with the invention, all of the staple guns are mounted for controlled vertical movement on their respective supports, to enable fastening devices to be inserted at two or more vertically spaced locations. To this end, immediately following the first actuation of the machine, the several staple guns are elevated (or lowered, as the case may be) to new, predetermined positions, and the guns are again actuated to insert additional fastening devices. As will be readily understood, the sequence of injecting fastening devices, changing the level of the guns, and then injecting additional fastening devices may be carried out as an automatic sequence, using simple timing devices, or these operations may be manually initiated, as desired.

For a better understanding of the invention, reference should be made to the following detailed description and to the accompanying drawing.

DESCRIPTION OF THE DRAWING FIG. 1 is a top plan view of a production assembly apparatus incorporating the principles of the invention, useful particularly for the staple gun assembly of drawer frames.

FIGS. 2, 3 and 4 are enlarged, fragmentary, cross-sectional views taken generally along lines 2-2, 33, and 4-4, respectively, of FIG. 1.

DESCRIPTION OF PREFERRED EMBODIMENT Referring now to the drawing, and initially to its 1 thereof, the reference numeral 10 designates generally a machine frame structure, typically a weldment of channels or other structural members. In a practical embodiment of the invention, the frame comprises a plurality of legs 11 supporting rectangularly arranged frame channels 12-15. A beam structure 16 extends between the frame channels 13, 15 and, for purposes of reference only, the beam structure 16 may be considered as extending transversely of the machine frame. As reflected in FIG. 2, the beam structure 16 may typically comprise a channel beam 17 secured with its open side facing downward and supporting a pair of channel beams 18, 19 secured with their open sides in facing relation.

For purposes of reference, the axis of the machine extending in the direction between the frame channels 12, 14 may be considered the longitudinal axis, and the channels 12, 14 as defining the ends of the machine. At one end of the machine there is provided a supporting structure which comprises the frame channel 12 and a similar channel beam 20 extending transversely of the machine, in spaced, parallel relation to the frame channel 12 and supported by the side frame channels l3, 15. In the illustrated arrangement, the structural elements 12, 20 comprise a fixed support 21. Desirably, each of the elements 12, 20 is a channel beam, arranged with its open side facing in an outward direction.

Adjacent the opposite end of the machine frame is a second support structure 22, consisting of a pair of outwardly facing channel beams 23, 24, corresponding generally in structure and configuration to the channel beams 12, 20. Instead of being secured to the frame channels 13, 15, however, the channel beams 23, 24 are secured at their ends by connecting blocks 25 and are slidably guided, for movement along the axis of the frame channels 13, 15, by means of guide rails 26, 27 secured to the top and bottom flanges of the channel beams 13, 15.

As shown in FIGS. 1 and 2, the connecting blocks 25, at the ends of the movable support 22, receive threaded shafts 28, 29 engaged by thrust bearings 30 mounted on the channel beam 14. One or both of the threaded shafts is provided with a crank or handwheel 31, and the two shafts are connected together by means of a synchronizing chain 32. Accordingly, by appropriate manipulation of the crank 31, the support 22 may be advanced or retracted in a longitudinal direction.

In accordance with one aspect of the invention, there is secured to the machine frame 10, advantageously by means of locating and securing bolts 33 extending into the main structure 16, an assembly jig designated generally by the reference numeral 34. In the illustrated form of the invention, the assembly jig 34 may typically comprise a flat base plate 35, to which are bolted a plurality of structural angle'ele'ments 36 arranged in rectangular configuration with their principal flanges extending vertically and forming reference rails. Mounted on the base plate 35, and spaced outwardly of the longitudinally disposed reference rails 36a are clamping springs 37 (see FIG. 4). These springs 37 are so arranged as to enable a machine operator to freely insert, between the springs and the opposed reference rails, boards 38, 39 forming two opposite side panels of a drawer frame to be assembled. Ideally, these springs 37 lightly but accurately hold the drawer panels 38, 39 against the reference members 36a. The side panels 38, 39 are designed to be of substantially the same length as the reference elements 36a.

After positioning the side panels 38, 39 of the intended drawer assembly, one of the end panels 40 may be positioned against a transverse reference element 36b. The end panel 40 is of a length to overlap the ends of the side panels 38, 39 and is accurately aligned with reference to the ends of these side panels by means of suitable end guides 36d.

When the end panel 40 is properly positioned, it is firmly clamped against the reference member 36b by means of a pair of air-actuated clamps 41, 42 carrying extendable clamping plungers 43, 44. The clamps 41, 42 are actuated by suitable control valves (not shown) located conveniently to the operator's access, when he has inserted the panel 40 in position.

At the opposite end of the assembly jig 34, there are provided air-actuated clamps 45, 46 corresponding to the clamps 41, 42, and these may be actuated by the operator, after first having positioned an end panel 47 against the transverse reference element 36c. Panel 47 corresponds generally to the panel 40, and is arranged in overlapping relation to the ends of the guide panels 38, 39 before being engaged by the clamps 45, 46.

At this juncture, all of the panels 3840 and 47 are being temporarily held in assembled relation, in readiness for permanent fastening.

In accordance with the invention, and as will be described in greater detail, staple guns 48-51 are arranged in alignment with the several joints to be secured. In the illustrated instance, since the fastening devices must be driven through the end panels 40, 47 and longitudinally into the side panels 38, 39, the staple guns are aligned with the respective side panels and disposed generally against the outer surfaces of the end panels. It is to be understood, of course, that, in the context of the present application, the term staple gun should be construed to include equivalent, alternative devices for inserting other types of fastening devices. However, conventional commercially available air-actuated staple guns presently are considered to be most suitable.

In accordance with one aspect of the invention, the staple guns 48-5l are mounted on carrier assembles 52-55, respectively, which in turn are carried by the channel beam supports 21, 22. As shown particularly in FIGS. 2 and 3, the staple gun carriers include a pair of clamping plates 56, 57 engaging the top and bottom flanges of the channel beam supports and secured together by a plurality of bolts 58. A fluid cylinder 59 has its cylinder body 60 supported by one or both of the plates 56, 57 and extending downwardly between the spaced webs of the channel beams 23, 24 (or 12, 20, as the case may be). As will be understood, by loosening of the bolts 58, the respective carriers may be adjusted transversely of the machine, and then secured in any position. In accordance with the invention, however, it is contemplated that, for general production purposes, the carriers 52 and 55 will be initially adjusted in predetermined alignment and thereafter not further adjusted (i.e., normally fixed). The various assembly jigs 34 to be utilized with the equipment, to accommodate various sizes and configurations of assembly parts desirably will be mounted on the beam structure 16 so that one of the assembly parts, corresponding to the panel 38, automatically will be aligned with the staple guns 4851 supported by the carriers 52-55. The remaining two carriers 53, 54 can be adjusted transversely to accommodate the configuration of a new production jig.

Each of the fluid cylinders 59 includes an extendable piston rod 61 which engages at its upper end a platform 62. The plat; form 62 is guided by guide rods 63, which are arranged in straddling relation to the piston rod 61 and pass through guide bearings 64 in the upper clamping plate 56. This arrangement accommodates and guides the vertical movement of the platform 62 between predetermined limit positions. The lower limit position, reflected by the dotted line position of the staple gun 48, in FIG. 2, may represent the fully retracted condition of the fluid cylinder 59, or may be defined by other suitable stops, as will be understood. The ti'pper limit position of platform 62 advantageously is determined by means of a pair of stop nuts 65 (FIG. 2) adjustably positioned on elongated reference bolts 66 which straddle the piston rod 61.

In the illustrated arrangement of apparatus, it is intended that the platform 62 have only two principal operating positions, an upper position and a lower position as just described, which may be achieved by actuation of the fluid cylinders 59 in one direction or the other to their limit positions. This is calculated to enable fastening elements to be inserted near the bottom and near the top of each joint, in accordance with customary assembly practice. It will be understood, however, that, if additional, intermediate fastening elements are desired to be utilized, provision may be made for the utilization of suitable retractable stop means or the like establishing an intermediate limit position, or through the utilization of means such as double-acting fluid cylinders, with suitable automatic or manual control.

As illustrated in FIG. 3, each of the platforms 62 typically include a pair of clamping blocks 67, 68 arranged to secure staple guns 48--51 of conventional configuration. As shown, these are desirably secured with their magazines 69 extending horizontally, so that the staple fasteners are oriented in a vertical plane for insertion into the assembled parts.

As indicated in FIG. 3, the upper clamping plate 56 of each carrier assembly projects in an inward direction beyond the inner edge 70 of the associated platform 62. On this projecting portion of the plate 56 there is a supporting bracket 71 which extends upward and mounts one of the air clamps 45, 46 or 41, 42. The vertical disposition of the air clamps is somewhat below the upper edges of the reference rails 36 of the assembly jig, as reflected in FIG. 2. Thus, in general, the height of the air clamps need not be adjustable to accommodate assembly jigs of different configuration.

The fixed association of the air clamps with the staple guns, on the individual carriers, enables the proper clamping arrangements to be established merely by effecting adjustment of the staple gun carriers themselves. In all cases, the air clamps will be effective on the assembly panels at a predetermined location adjacent to the point of fastening.

SUMMARY OF OPERATION In the setup and operation of the equipment for typical production runs, an appropriate assembly jig 34 is first mounted on a beam structure 16. The location of the mounting holes for the assembly jig (receiving bolts 33) is such that the assembly joint at the upper right in FIG. 1 automatically is aligned with the normally fixed staple gun 51. The initial alignment automatically is such that, when the staple gun is in its lower limit position, the staple gun is positioned to insert a fastening at a proper lower level in the joint. Dependingupon the height of the panels to be assembled, the upper limit of travel of the platform 62 may have to be adjusted, by means of the stop nuts 65. If so, this adjustment is made for the carriage 55, as well as for the other carriages 52-54. Proper positioning of the staple gun 50 is effected by loosening the bolts 58 and transversely shifting the carriage 54 along its support 21, and then relocking it in its adjusted position. Angular adjustment of the guns may be effected by loosening of the clamping blocks 68, setting the guns in desired orientation and then retightening the clamping blocks.

The staple gun 48, with its carrier 52 secured to the support 22, automatically is properly aligned with the joint with which it is associated and it is normally fixed on the support. However, depending upon the length of the assembly, the gun 48 may have to be adjusted longitudinally. This is effected expeditiously by bodily shifting the support 22 in a longitudinal direction by manipulation of the threaded shafts 28, 29. At this point, the only adjustment remaining is the transverse adjustment of the carrier 53 along its support 22, which is performed in the same manner as described with respect to the carrier 54.

With all the staple guns thus expeditiously aligned, the operator may proceed to insert the assembly panels 38, 39, and then the panels 40, 47. The air clamps 41, 42 and 45, 46 are now actuated, and this may be accomplished by actuation of a single air valve (not shown). In this respect, it will be observed that the positioning of the staple gun carriers 52-55 automatically effected proper positioning of the air clamps, so that no separate manipulation of these elements was required.

With the assembly parts now properly clamped. an air valve 72 (FIG. I) may be actuated by the machine operator, effecting simultaneous actuation of all four of the staple guns to set fastening devices into the assembled joints. At this stage, of course, all the guns are in their lower limit positions. Immediately thereafter, the operator actuates a further air valve 73, simultaneously actuating the several platform cylinders 59, raising all of the guns simultaneously to their upper limit positions determined by settings of the stop nuts 65. While the platform cylinders remain thus energized, the air valve 72 is again actuated, causing all the staple guns to set fastening devices in the upper areas of the assembled joints. The valve 73 may now be actuated to lower or retract the platform cylinder, and the air clamps also are released, enabling the assembled drawer frame to be removed from its assembly jig. The jig then is ready for reloading for a further production sequence. If desired, of course, the assembly jig itself may be raised or lowered, while the guns remain stationary. Also, it is contemplated that additional jigs may be employed, to be loaded externally and delivered to the fastening position by suitable transfer or conveyor means.

As will be readily appreciated, the sequence of actuating the air clamps, setting fasteners at the lower level, extending the platform cylinders, setting fastening elements at the upper level, retracting the platform cylinders, and releasing the air clamps can readily be performed in a controlled sequence, if desired, through the use of a simple cycle timer arrangement in conjunction with appropriate solenoid valves. It will also be understood that, while the illustrated equipment utilizes four staple guns, a smaller or larger number of guns may be used, depending upon the number of parts to be assembled and the configuration of the final assembly.

The equipment of the invention is of an extremely simplified, yet rugged and dependable construction, which would be made available to the production manufacturer at a low initial cost. Its various adjustment facilities are so expeditiously utilized as to enable the equipment to be set up for various production assemblies in a practicable minimum of time. This is of particular importance for furniture production, for example, where production runs may be relatively short and setup operations have to be performed with relative frequence.

It should be understood, of course, that the specific form of the invention herein illustrated and described is intended to be representative only, as certain changes may be made therein without departing from the clear teachings of the disclosure. Accordingly, reference should be made to the following appended claims in determining the full scope of the invention. In the description and claims, the term furniture or the like" is intended to be inclusive of any assembly of parts, of wood or other material, which is capable of being secured by driven fastening devices. Likewise, the term staple gun" is intended to include any mechanism for forcibly inserting a fastening device, such as a nail or staple. Moreover, it will be appreciated that in certainassembly applications using materials which may be welded. riveted, or adhesrvely secured in addition to or in lieu of being fastenable by staples, staple guns" as defined herein, would embrace spotwelding guns, riveting guns, and/or gluing guns (adhesive applicators).

We claim:

I. A machine for the production assembly of articles of furniture or the like. which comprises,

a. a machine frame,

b. an assemblyjig mounted by said machine frame and having means for the reception of assembly parts and the temporary maintenance thereof in assembled relation,

c. a first support carried by said machine frame and extending transversely across said frame adjacent one side of said assembly jig,

. a pair of staple gun carriers mounted on said first support, and at least one of said carriers being transversely movable to, and securable in, predetermined assembly positions on said first support,

e. a second support carried by said machine frame and extending transversely across said frame adjacent the opposite side of said assembly jig,

f. a pair of staple gun carriers mounted on said second support, and at least one of said carriers being transversely movable to, and securable in, predetermined assembly positions on said second support,

g. means mounting said second support for longitudinal movement in said machine frame to predetermined assembly positions,

h. a staple gun carried by each of said carriers and positioned to inject a fastening element into the temporarily maintained assembly parts in said jig,

. said carriers being mounted for predetermined vertical movement on said supports during assembly operations, whereby said assembly parts may be secured at a plurality of levels by each staple gun during an assembly operation.

2. A machine according to claim 1, further characterized by said staple gun carriers each comprising,

a. a plate adjustably positioned on said machine frame,

b. a fluid cylinder carried by said plate,

c. a gun platform carried by said fluid cylinder for vertical movement, and

d. stop means for limiting the upper and lower positions of said platforms.

3. A machine according to claim 2, further characterized by clamping means being mounted on the cylinder carrying plates of at least certain ones of said carriers and being movable therewith during adjustment.

4. A machine according to claim 2, further characterized by a. said supports comprising spaced, parallel structural elements having facing vertical web portions and horizontal flanges,

b. said carrier plates being supported by said flanges, and

c. the bodies of said fluid cylinders extending downward between said web portions.

5. A machine according to claim 1, further characterized by a. one of said supports being fixed to said machine frame,

b. the other of said supports being longitudinally movable relative to the machine frame,

c. a staple gun carrier being mounted in normally fixed relation to each of said supports, and

cl. a staple gun carrier being mounted in normally adjustable relation to each of said supports.

6. A machine according to claim 5, further characterized by said machine frame including a mounting structure for the removable support of said assembly jig,

said mounting structure being adapted to receive and secure a plurality of different assembly jigs, one at a time, c. said mounting structure and said assembly jig having interengaging receiving and locating means for positioning each assembly jig in predetermined alignment with the normally fixed carrier secured to the fixed support. 

1. A machine for the production assembly of articles of furniture or the like, which comprises, a. a machine frame, b. an assembly jig mounted by said machine frame and having means for the reception of assembly parts and the temporary maintenance thereof in assembled relation, c. a first support carried by said machine frame and extending transversely across said frame adjacent one side of said assembly jig, d. a pair of staple gun carriers mounted on said first support, and at least one of said carriers being transversely movable to, and securable in, predetermined assembly positions on said first support, e. a second support carried by said machine frame and extending transversely across said frame adjacent the opposite side of said assembly jig, f. a pair of staple gun carriers mounted on said second support, and at least one of said carriers being transversely movable to, and securable in, predetermined assembly positions on said second support, g. means mounting said second support for longitudinal movement in said machine frame to predetermined assembly positions, h. a staple gun carried by each of said carriers and positioned to inject a fastening element into the temporarily maintained assembly parts in said jig, i. said carriers being mounted for predetermined vertical movement on said supports during assembly operations, whereby said assembly parts may be secured at a plurality of levels by each staple gun during an assembly operation.
 2. A machine according to claim 1, further characterized by said staple gun carriers each comprising, a. a plate adjustably positioned on said machine frame, b. a fluid cylinder carried by said plate, c. a gun platform carried by said fluid cylinder for vertical movement, and d. stop means for limiting the upper and lower positions of said platforms.
 3. A machine according to claim 2, further characterized by clamping means being mounted on the cylinder carrying plates of at least certain ones of said carriers and being movable therewith during adjustment.
 4. A machine according to claim 2, further characterized by a. said supports comprising spaced, parallel structural elements having facing vertical web portions and horizontal flanges, b. said carrier plates being supported by said flanges, and c. the bodies of said fluid cylinders extending downward between said web portions.
 5. A machine according to claim 1, further characterized by a. one of said supports being fixed to said machine frame, b. the other of said supports being longitudinally movable relative to the machine frame, c. a staple gun carrier being mounted in normally fixed relation to each of said supports, and d. a staple gun carrier being mounted in normally adjustable relation to each of said supports.
 6. A machine according to claim 5, further characterized by a. said machine frame including a mounting structure for the removable support of said assembly jig, b. said mounting structure being adapted to receive and secure a plurality of different assembly jigs, one at a time, c. said mounting structure and said assembly jig having interengaging receiving and locating means for positioning each assembly jig in predetermined alignment with the normally fixed carrier secured to the fixed support. 